JP5319380B2 - Low basis weight air filter media - Google Patents
Low basis weight air filter media Download PDFInfo
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- JP5319380B2 JP5319380B2 JP2009106738A JP2009106738A JP5319380B2 JP 5319380 B2 JP5319380 B2 JP 5319380B2 JP 2009106738 A JP2009106738 A JP 2009106738A JP 2009106738 A JP2009106738 A JP 2009106738A JP 5319380 B2 JP5319380 B2 JP 5319380B2
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- 239000000835 fiber Substances 0.000 claims description 222
- 239000011230 binding agent Substances 0.000 claims description 67
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 claims description 59
- 230000002209 hydrophobic effect Effects 0.000 claims description 39
- 239000003365 glass fiber Substances 0.000 claims description 31
- 239000005871 repellent Substances 0.000 claims description 15
- 230000002940 repellent Effects 0.000 claims description 14
- 229920003002 synthetic resin Polymers 0.000 claims description 13
- 239000000057 synthetic resin Substances 0.000 claims description 13
- 238000012360 testing method Methods 0.000 claims description 10
- 239000002994 raw material Substances 0.000 claims description 9
- 238000000034 method Methods 0.000 description 25
- 230000000052 comparative effect Effects 0.000 description 24
- 230000000694 effects Effects 0.000 description 20
- 229920002994 synthetic fiber Polymers 0.000 description 20
- 239000012209 synthetic fiber Substances 0.000 description 20
- 239000005388 borosilicate glass Substances 0.000 description 17
- 238000002156 mixing Methods 0.000 description 17
- 239000000203 mixture Substances 0.000 description 17
- 239000011521 glass Substances 0.000 description 11
- 229920000728 polyester Polymers 0.000 description 11
- 238000001914 filtration Methods 0.000 description 10
- NIXOWILDQLNWCW-UHFFFAOYSA-N acrylic acid group Chemical group C(C=C)(=O)O NIXOWILDQLNWCW-UHFFFAOYSA-N 0.000 description 9
- 230000007423 decrease Effects 0.000 description 9
- -1 polypropylene Polymers 0.000 description 9
- 229920005989 resin Polymers 0.000 description 9
- 239000011347 resin Substances 0.000 description 9
- 239000000463 material Substances 0.000 description 8
- 239000007788 liquid Substances 0.000 description 7
- 239000002245 particle Substances 0.000 description 7
- 239000004372 Polyvinyl alcohol Substances 0.000 description 6
- 239000003795 chemical substances by application Substances 0.000 description 6
- 229920002451 polyvinyl alcohol Polymers 0.000 description 6
- 238000002834 transmittance Methods 0.000 description 6
- YCKRFDGAMUMZLT-UHFFFAOYSA-N Fluorine atom Chemical compound [F] YCKRFDGAMUMZLT-UHFFFAOYSA-N 0.000 description 5
- 229920002978 Vinylon Polymers 0.000 description 5
- 238000013329 compounding Methods 0.000 description 5
- 239000011737 fluorine Substances 0.000 description 5
- 229910052731 fluorine Inorganic materials 0.000 description 5
- 238000009987 spinning Methods 0.000 description 5
- 239000004925 Acrylic resin Substances 0.000 description 4
- 229920000178 Acrylic resin Polymers 0.000 description 4
- QAOWNCQODCNURD-UHFFFAOYSA-N Sulfuric acid Chemical compound OS(O)(=O)=O QAOWNCQODCNURD-UHFFFAOYSA-N 0.000 description 4
- 238000001035 drying Methods 0.000 description 4
- 239000000428 dust Substances 0.000 description 4
- 238000004519 manufacturing process Methods 0.000 description 4
- 229920000297 Rayon Polymers 0.000 description 3
- 230000002378 acidificating effect Effects 0.000 description 3
- 238000007865 diluting Methods 0.000 description 3
- 239000004065 semiconductor Substances 0.000 description 3
- 239000000243 solution Substances 0.000 description 3
- 239000000126 substance Substances 0.000 description 3
- 238000010998 test method Methods 0.000 description 3
- RNFJDJUURJAICM-UHFFFAOYSA-N 2,2,4,4,6,6-hexaphenoxy-1,3,5-triaza-2$l^{5},4$l^{5},6$l^{5}-triphosphacyclohexa-1,3,5-triene Chemical compound N=1P(OC=2C=CC=CC=2)(OC=2C=CC=CC=2)=NP(OC=2C=CC=CC=2)(OC=2C=CC=CC=2)=NP=1(OC=1C=CC=CC=1)OC1=CC=CC=C1 RNFJDJUURJAICM-UHFFFAOYSA-N 0.000 description 2
- ZOXJGFHDIHLPTG-UHFFFAOYSA-N Boron Chemical compound [B] ZOXJGFHDIHLPTG-UHFFFAOYSA-N 0.000 description 2
- 239000004743 Polypropylene Substances 0.000 description 2
- 239000002253 acid Substances 0.000 description 2
- 125000003545 alkoxy group Chemical group 0.000 description 2
- 238000007664 blowing Methods 0.000 description 2
- 229910052796 boron Inorganic materials 0.000 description 2
- 238000004040 coloring Methods 0.000 description 2
- 150000001875 compounds Chemical class 0.000 description 2
- 230000003247 decreasing effect Effects 0.000 description 2
- 239000000839 emulsion Substances 0.000 description 2
- 239000003063 flame retardant Substances 0.000 description 2
- 235000013305 food Nutrition 0.000 description 2
- 238000005470 impregnation Methods 0.000 description 2
- 239000004816 latex Substances 0.000 description 2
- 229920000126 latex Polymers 0.000 description 2
- 230000035699 permeability Effects 0.000 description 2
- 230000000704 physical effect Effects 0.000 description 2
- 229920001155 polypropylene Polymers 0.000 description 2
- 239000011148 porous material Substances 0.000 description 2
- 229920002050 silicone resin Polymers 0.000 description 2
- 235000002639 sodium chloride Nutrition 0.000 description 2
- 229920002972 Acrylic fiber Polymers 0.000 description 1
- 229920000742 Cotton Polymers 0.000 description 1
- IMROMDMJAWUWLK-UHFFFAOYSA-N Ethenol Chemical group OC=C IMROMDMJAWUWLK-UHFFFAOYSA-N 0.000 description 1
- 229920001410 Microfiber Polymers 0.000 description 1
- OAICVXFJPJFONN-UHFFFAOYSA-N Phosphorus Chemical compound [P] OAICVXFJPJFONN-UHFFFAOYSA-N 0.000 description 1
- 239000004698 Polyethylene Substances 0.000 description 1
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 1
- FAPWRFPIFSIZLT-UHFFFAOYSA-M Sodium chloride Chemical compound [Na+].[Cl-] FAPWRFPIFSIZLT-UHFFFAOYSA-M 0.000 description 1
- 229920002472 Starch Polymers 0.000 description 1
- 239000000654 additive Substances 0.000 description 1
- 239000000853 adhesive Substances 0.000 description 1
- 239000000443 aerosol Substances 0.000 description 1
- 238000004378 air conditioning Methods 0.000 description 1
- 238000004887 air purification Methods 0.000 description 1
- 239000003513 alkali Substances 0.000 description 1
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
- 229910052782 aluminium Inorganic materials 0.000 description 1
- 239000002518 antifoaming agent Substances 0.000 description 1
- 239000003963 antioxidant agent Substances 0.000 description 1
- 230000003078 antioxidant effect Effects 0.000 description 1
- 239000002216 antistatic agent Substances 0.000 description 1
- 239000007864 aqueous solution Substances 0.000 description 1
- 230000005540 biological transmission Effects 0.000 description 1
- 238000005282 brightening Methods 0.000 description 1
- 239000002131 composite material Substances 0.000 description 1
- 238000011109 contamination Methods 0.000 description 1
- 230000001276 controlling effect Effects 0.000 description 1
- 239000003431 cross linking reagent Substances 0.000 description 1
- 238000007766 curtain coating Methods 0.000 description 1
- 230000001877 deodorizing effect Effects 0.000 description 1
- 239000006185 dispersion Substances 0.000 description 1
- 238000004090 dissolution Methods 0.000 description 1
- 238000002036 drum drying Methods 0.000 description 1
- 238000000578 dry spinning Methods 0.000 description 1
- 238000010292 electrical insulation Methods 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 239000003822 epoxy resin Substances 0.000 description 1
- 238000011156 evaluation Methods 0.000 description 1
- 239000011152 fibreglass Substances 0.000 description 1
- 239000010419 fine particle Substances 0.000 description 1
- 239000003205 fragrance Substances 0.000 description 1
- 229910052736 halogen Inorganic materials 0.000 description 1
- 150000002367 halogens Chemical class 0.000 description 1
- LNEPOXFFQSENCJ-UHFFFAOYSA-N haloperidol Chemical compound C1CC(O)(C=2C=CC(Cl)=CC=2)CCN1CCCC(=O)C1=CC=C(F)C=C1 LNEPOXFFQSENCJ-UHFFFAOYSA-N 0.000 description 1
- 238000007602 hot air drying Methods 0.000 description 1
- 239000012943 hotmelt Substances 0.000 description 1
- 238000007603 infrared drying Methods 0.000 description 1
- 239000012784 inorganic fiber Substances 0.000 description 1
- 229910010272 inorganic material Inorganic materials 0.000 description 1
- 239000011147 inorganic material Substances 0.000 description 1
- 238000011835 investigation Methods 0.000 description 1
- 239000004973 liquid crystal related substance Substances 0.000 description 1
- 238000005259 measurement Methods 0.000 description 1
- 238000002074 melt spinning Methods 0.000 description 1
- 239000003658 microfiber Substances 0.000 description 1
- 239000006082 mold release agent Substances 0.000 description 1
- 239000004745 nonwoven fabric Substances 0.000 description 1
- 238000010943 off-gassing Methods 0.000 description 1
- 230000035515 penetration Effects 0.000 description 1
- 229910052698 phosphorus Inorganic materials 0.000 description 1
- 239000011574 phosphorus Substances 0.000 description 1
- 239000000049 pigment Substances 0.000 description 1
- 239000004014 plasticizer Substances 0.000 description 1
- 229920000647 polyepoxide Polymers 0.000 description 1
- 229920000573 polyethylene Polymers 0.000 description 1
- 229920000098 polyolefin Polymers 0.000 description 1
- 229920005672 polyolefin resin Polymers 0.000 description 1
- 239000003755 preservative agent Substances 0.000 description 1
- 238000012545 processing Methods 0.000 description 1
- 230000002285 radioactive effect Effects 0.000 description 1
- 239000002964 rayon Substances 0.000 description 1
- 230000001105 regulatory effect Effects 0.000 description 1
- 230000003014 reinforcing effect Effects 0.000 description 1
- 230000000979 retarding effect Effects 0.000 description 1
- 150000003839 salts Chemical class 0.000 description 1
- 238000007789 sealing Methods 0.000 description 1
- 239000011780 sodium chloride Substances 0.000 description 1
- 239000007787 solid Substances 0.000 description 1
- 239000002904 solvent Substances 0.000 description 1
- 238000005507 spraying Methods 0.000 description 1
- 239000008107 starch Substances 0.000 description 1
- 235000019698 starch Nutrition 0.000 description 1
- 239000004094 surface-active agent Substances 0.000 description 1
- 229920001059 synthetic polymer Polymers 0.000 description 1
- 229920001169 thermoplastic Polymers 0.000 description 1
- 229920002803 thermoplastic polyurethane Polymers 0.000 description 1
- 239000004416 thermosoftening plastic Substances 0.000 description 1
- 239000002562 thickening agent Substances 0.000 description 1
- 239000006097 ultraviolet radiation absorber Substances 0.000 description 1
- 238000011144 upstream manufacturing Methods 0.000 description 1
- 238000002166 wet spinning Methods 0.000 description 1
- 239000000080 wetting agent Substances 0.000 description 1
- 239000002023 wood Substances 0.000 description 1
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D39/00—Filtering material for liquid or gaseous fluids
- B01D39/14—Other self-supporting filtering material ; Other filtering material
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D39/00—Filtering material for liquid or gaseous fluids
- B01D39/14—Other self-supporting filtering material ; Other filtering material
- B01D39/16—Other self-supporting filtering material ; Other filtering material of organic material, e.g. synthetic fibres
- B01D39/1607—Other self-supporting filtering material ; Other filtering material of organic material, e.g. synthetic fibres the material being fibrous
- B01D39/1623—Other self-supporting filtering material ; Other filtering material of organic material, e.g. synthetic fibres the material being fibrous of synthetic origin
- B01D39/163—Other self-supporting filtering material ; Other filtering material of organic material, e.g. synthetic fibres the material being fibrous of synthetic origin sintered or bonded
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D39/00—Filtering material for liquid or gaseous fluids
- B01D39/14—Other self-supporting filtering material ; Other filtering material
- B01D39/20—Other self-supporting filtering material ; Other filtering material of inorganic material, e.g. asbestos paper, metallic filtering material of non-woven wires
- B01D39/2003—Glass or glassy material
- B01D39/2017—Glass or glassy material the material being filamentary or fibrous
- B01D39/2024—Glass or glassy material the material being filamentary or fibrous otherwise bonded, e.g. by resins
-
- D—TEXTILES; PAPER
- D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
- D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
- D21H13/00—Pulp or paper, comprising synthetic cellulose or non-cellulose fibres or web-forming material
- D21H13/02—Synthetic cellulose fibres
- D21H13/04—Cellulose ethers
-
- D—TEXTILES; PAPER
- D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
- D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
- D21H13/00—Pulp or paper, comprising synthetic cellulose or non-cellulose fibres or web-forming material
- D21H13/10—Organic non-cellulose fibres
-
- D—TEXTILES; PAPER
- D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
- D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
- D21H13/00—Pulp or paper, comprising synthetic cellulose or non-cellulose fibres or web-forming material
- D21H13/36—Inorganic fibres or flakes
- D21H13/38—Inorganic fibres or flakes siliceous
- D21H13/40—Inorganic fibres or flakes siliceous vitreous, e.g. mineral wool, glass fibres
-
- D—TEXTILES; PAPER
- D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
- D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
- D21H27/00—Special paper not otherwise provided for, e.g. made by multi-step processes
- D21H27/08—Filter paper
-
- D—TEXTILES; PAPER
- D21—PAPER-MAKING; PRODUCTION OF CELLULOSE
- D21H—PULP COMPOSITIONS; PREPARATION THEREOF NOT COVERED BY SUBCLASSES D21C OR D21D; IMPREGNATING OR COATING OF PAPER; TREATMENT OF FINISHED PAPER NOT COVERED BY CLASS B31 OR SUBCLASS D21G; PAPER NOT OTHERWISE PROVIDED FOR
- D21H5/00—Special paper or cardboard not otherwise provided for
- D21H5/12—Special paper or cardboard not otherwise provided for characterised by the use of special fibrous materials
- D21H5/20—Special paper or cardboard not otherwise provided for characterised by the use of special fibrous materials of organic non-cellulosic fibres too short for spinning, with or without cellulose fibres
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D2239/00—Aspects relating to filtering material for liquid or gaseous fluids
- B01D2239/04—Additives and treatments of the filtering material
- B01D2239/0457—Specific fire retardant or heat resistant properties
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D2239/00—Aspects relating to filtering material for liquid or gaseous fluids
- B01D2239/08—Special characteristics of binders
- B01D2239/086—Binders between particles or fibres
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01D—SEPARATION
- B01D2239/00—Aspects relating to filtering material for liquid or gaseous fluids
- B01D2239/12—Special parameters characterising the filtering material
- B01D2239/1233—Fibre diameter
Landscapes
- Chemical & Material Sciences (AREA)
- Chemical Kinetics & Catalysis (AREA)
- Inorganic Chemistry (AREA)
- Life Sciences & Earth Sciences (AREA)
- Geology (AREA)
- Filtering Materials (AREA)
- Paper (AREA)
Description
本発明は、エアフィルタ用濾材、特に半導体、液晶、バイオ・食品工業関係のクリーンルーム、クリーンベンチ等の空気浄化施設用途のエアフィルタ、ビル空調用エアフィルタ又は空気清浄機用途のエアフィルタなどにおいて、気体中の微粒子を濾過するために使用される準高性能エアフィルタ用濾材又は高性能エアフィルタ用濾材に関する。 The present invention is a filter medium for air filters, particularly semiconductors, liquid crystals, clean rooms for bio / food industries, air filters for air purification facilities such as clean benches, air filters for building air conditioning or air filters for air purifiers, etc. The present invention relates to a filter medium for a semi-high performance air filter or a filter medium for a high performance air filter used for filtering fine particles in a gas.
従来、空気中のサブミクロン乃至ミクロン単位の粒子を効率的に捕集するために、エアフィルタの捕集技術が用いられている。エアフィルタは、その対象とする粒子径や除塵効率の違いによって粗塵用フィルタ、中性能フィルタ、準高性能フィルタ、高性能フィルタ(HEPAフィルタ、ULPAフィルタ)などに大別される。 2. Description of the Related Art Conventionally, air filter collection techniques are used to efficiently collect submicron to micron particles in air. Air filters are roughly classified into coarse dust filters, medium performance filters, semi-high performance filters, high performance filters (HEPA filters, ULPA filters), etc., depending on the target particle size and dust removal efficiency.
このうち、準高性能フィルタ、高性能フィルタの規格としては、欧州規格のEN1822がある。EN1822においては最大透過粒径(MPPS)における捕集効率のレベルにより、U16からH10まで7段階に分類されている。その他、高性能フィルタの規格としては、米国のIEST‐RP‐CC001、日本のJIS Z 4812:1995「放射性エアロゾル用高性能エアフィルタ」などがある。そして、準高性能フィルタ、高性能フィルタに使用される濾材としては、これら規格をエアフィルタとして満足するものが使用されている。濾材の素材としては、不織布状のガラス繊維製エアフィルタ用濾材が多く使われており、主要構成物として平均繊維径がサブマイクロメートル〜約3マイクロメートルのガラス短繊維が用いられている。 Among them, the standard for semi-high performance filters and high performance filters is EN1822 of the European standard. EN1822 is classified into seven stages from U16 to H10 depending on the level of collection efficiency at the maximum transmission particle size (MPPS). Other high-performance filter standards include IEST-RP-CC001 in the US and JIS Z 4812: 1995 “High-performance air filter for radioactive aerosol” in Japan. And as a filter medium used for a semi-high performance filter and a high performance filter, what satisfies these standards as an air filter is used. As a material for the filter medium, a non-woven glass fiber air filter medium is often used, and a glass short fiber having an average fiber diameter of submicrometer to about 3 micrometers is used as a main component.
また、クリーンルームで使用されるエアフィルタ用濾材は、必要に応じて、撥水性が付与される。なお、本発明における撥水性とは、MIL−STD−282の測定法によって規定されるものである。濾材に撥水性を付与する目的としては、濾材を加工するときに使用するシール剤、ホットメルトなどの染み込みを防ぐことや、温度変化によって水分が結露した場合においても、そのまま濾材を使用できるようにすることなどが挙げられる。また、海塩粒子が多く存在するような環境下において塩分の潮解を防ぐためには、高い撥水性を有する濾材が必要とされている。 Moreover, the filter medium for air filters used in a clean room is provided with water repellency as needed. In addition, the water repellency in this invention is prescribed | regulated by the measuring method of MIL-STD-282. For the purpose of imparting water repellency to the filter media, the filter media can be used as it is even when the sealing agent used when processing the filter media, preventing penetration of hot melt, etc., or when moisture condenses due to temperature changes. To do. Further, in order to prevent salt deliquescence in an environment where many sea salt particles exist, a filter medium having high water repellency is required.
エアフィルタ用濾材は、濾過面積を大きくするためプリーツ加工機でジグザグ状に折り加工され、アルミ製、木製、樹脂製などの枠内に収められてエアフィルタユニットとなる。エアフィルタユニットのサイズとしては、縦×横で610mm×610mmの大きさが標準的ではあるが、その目的によってさまざまである。また、エアフィルタユニットの奥行きもさまざまである。 In order to increase the filtration area, the air filter medium is folded into a zigzag shape by a pleating machine, and is housed in a frame made of aluminum, wood, resin, or the like to form an air filter unit. As the size of the air filter unit, a size of 610 mm × 610 mm in length × width is standard, but varies depending on the purpose. Also, the depth of the air filter unit varies.
エアフィルタ用濾材に関する先行技術としては、例えば次のものがある。ガラス繊維製エアフィルタ用濾材の強度改善策として、特定の繊維径を有するガラス繊維、ポリプロピレン繊維、熱可塑性成分をその一部として含むポリオレフィン系複合繊維、並びに65重量%以上ビニルアルコール単位を含有する長鎖状合成高分子で、水中溶解温度が50〜100℃であるビニロンバインダー繊維で構成され、かつ、濾材中のガラス繊維の配合比率が0.5〜20重量%、ビニロンバインダー繊維の配合比率が0.5〜10重量%であることを特徴とする濾材及びその製造方法(例えば、特許文献1を参照。)が提案されている。また、直径4μm以下の極細ガラス繊維60〜97重量%、0.05〜0.5デニールの細デニルポリビニルアルコール系繊維、ポリビニルアルコール系繊維状バインダー0〜7重量%からなり、坪量が25〜150g/m2であるエアフィルタ用濾材が提案されている(例えば、特許文献2を参照。)。 Examples of the prior art relating to the filter medium for air filters include the following. As a measure for improving the strength of the filter material for glass fiber air filter, glass fiber having a specific fiber diameter, polypropylene fiber, polyolefin-based composite fiber including a thermoplastic component as a part thereof, and containing 65% by weight or more vinyl alcohol unit. It is a long-chain synthetic polymer and is composed of vinylon binder fibers having a dissolution temperature in water of 50 to 100 ° C., and the mixing ratio of glass fibers in the filter medium is 0.5 to 20% by weight, and the mixing ratio of vinylon binder fibers Has been proposed, and a method for producing the same (see, for example, Patent Document 1). Further, it consists of 60 to 97% by weight of ultrafine glass fiber having a diameter of 4 μm or less, 0.05 to 0.5 denier fine denenyl polyvinyl alcohol fiber, and 0 to 7% by weight of polyvinyl alcohol fibrous binder, and the basis weight is 25. A filter medium for an air filter that is ˜150 g / m 2 has been proposed (see, for example, Patent Document 2).
さらに、気体中の粉塵を濾過するときの通常の通過方向と逆方向に気体を吹いて逆流させることで、表面に付着した捕集粉塵を払い落として濾過機能を回復させるバグフィルタ用濾材において、湿式抄紙法によって5μm以下の微細合成繊維と1μm以下のガラス繊維とを繊維バインダーと共に混抄した濾過層と、この濾過層に接合され、かつ、これを支持して補強する強度維持層とを備えたことを特徴とするバグフィルタ用濾材が提案されている(例えば、特許文献3を参照。)。 Furthermore, in the filter material for bag filter that recovers the filtration function by blowing off the collected dust adhering to the surface by blowing the gas in the reverse direction to the normal passing direction when filtering the dust in the gas, A filtration layer obtained by mixing fine synthetic fibers of 5 μm or less and glass fibers of 1 μm or less together with a fiber binder by a wet papermaking method, and a strength maintaining layer bonded to the filtration layer and supporting and reinforcing it. A filter material for a bag filter characterized by this is proposed (see, for example, Patent Document 3).
本願発明者らは、過去、従来の濾材に比較して濾材の強度と撥水性を向上させ、低圧損化・高捕集効率化させるため、濾材を構成するガラス繊維に有機系バインダーとポリイソシアネート化合物及び撥水剤を付着させてなるエアフィルタ用濾材とその製造方法を提供した(例えば、特許文献4を参照。)。 In the past, the present inventors have improved the strength and water repellency of a filter medium as compared with conventional filter media, and reduced the pressure loss and increased the collection efficiency. A filter medium for an air filter formed by adhering a compound and a water repellent and a method for producing the same were provided (for example, see Patent Document 4).
また、従来ガラス繊維を主体繊維とするエアフィルタ濾材への撥水性付与の方法として、シリコーン系樹脂で構成される撥水剤の使用(例えば、特許文献5を参照。)、又はフッ素系樹脂で構成される撥水剤の使用(例えば、特許文献6を参照。)が行われてきた。本願発明者らも過去、ガラス繊維表面にアルキルケテンダイマーを付着形成させたことを特徴とするエアフィルタ用濾材(例えば、特許文献7を参照。)や、低分子環状シロキサンを主とした有機アウトガスを発生させない撥水剤として、少なくとも分子内に三つ以上のアルコキシ基を有するアルコキシシランを加水分解したのち縮合した、縮合物を前記ガラス繊維表面に付着形成させたことを特徴とするアウトガスの少ないエアフィルタ用濾材(例えば、特許文献8を参照。)を提案した。 In addition, as a method for imparting water repellency to an air filter medium mainly composed of glass fiber, the use of a water repellent composed of a silicone resin (see, for example, Patent Document 5), or a fluorine resin. The use of constructed water repellents (see, for example, Patent Document 6) has been performed. In the past, the inventors of the present application also used an air filter medium (see, for example, Patent Document 7), which is characterized in that an alkyl ketene dimer is adhered and formed on the glass fiber surface, and an organic outgas mainly composed of low molecular cyclic siloxane. As a water-repellent agent that does not generate water, at least three alkoxy groups having at least three alkoxy groups in the molecule are hydrolyzed and condensed to form a condensate on the glass fiber surface, resulting in low outgassing An air filter medium (see, for example, Patent Document 8) has been proposed.
近年、エアフィルタユニットの軽量化、コンパクト化の目的で、奥行きの薄いタイプが望まれているが、ユニットに同じ濾過面積のプリーツした濾材を収めようとすると、濾材の厚みのためにプリーツした濾材面が互いに接触して構造抵抗を引き起こすことでエアフィルタユニットの圧力損失が著しく増大してしまう問題があった。 In recent years, for the purpose of reducing the weight and compactness of air filter units, a type with a small depth has been desired, but when trying to store pleated filter media of the same filtration area in the unit, the filter media pleated due to the thickness of the filter media There is a problem that the pressure loss of the air filter unit is remarkably increased by causing the surfaces to contact each other and causing structural resistance.
この問題を解決するため、エアフィルタ用濾材の厚さを薄くする、すなわち坪量を低減しようとする試みがある。しかし、ガラス繊維製濾材は、他の有機素材の濾材に比べて脆弱である。このため、通常、濾材坪量を60〜80g/m2程度のものとするが、これを50g/m2以下にしようとするとこれに伴って濾材強度が低下し、プリーツ加工時やエアフィルタとしての実使用時に濾材が破れやすくなる問題があった。また、濾材撥水性も同様に、濾材の低坪量化によって低下する問題があった。 In order to solve this problem, there is an attempt to reduce the thickness of the air filter medium, that is, to reduce the basis weight. However, glass fiber filter media are more fragile than other organic filter media. Therefore, usually, the filter medium basis weight is assumed about 60~80g / m 2, which filter medium strength decreases along with this when you try to 50 g / m 2 or less, as pleating or when the air filter In actual use, there was a problem that the filter medium was easily broken. In addition, the water repellency of the filter medium also has a problem of decreasing due to the low basis weight of the filter medium.
本発明者らの検討では、前述した濾材の破れはJIS P 8116:2000「紙‐引裂強さ試験方法‐エルメンドルフ形引裂試験機法」に規定するところの紙の引裂強さが深く影響していることが分かり、引裂強さが坪量に比例して低下するため破れが発生しやすくなることが分かっている。また、撥水性についても、坪量の低減とともに濾材の厚さが薄くなり、水が浸透しやすくなるため低下することが分かっている。 According to the study by the present inventors, the tearing of the filter medium described above is greatly influenced by the tear strength of paper as defined in JIS P 8116: 2000 “Paper-Tear Strength Test Method—Elmendorf Tear Test Machine Method”. It is known that tearing tends to occur because the tear strength decreases in proportion to the basis weight. In addition, it has been found that the water repellency also decreases because the filter medium becomes thinner and the water easily penetrates as the basis weight decreases.
過去、ガラス繊維製エアフィルタ用濾材の強度改善策として特許文献1又は2の技術があるが、当該の特許文献実施例において、引張強さの向上効果が認められるものの、濾材の引裂強さは向上せず、プリーツ加工時や実使用時の濾材の破れにはあまり効果が無く、撥水性の向上効果もないという問題がある。 In the past, there is a technique of Patent Document 1 or 2 as a measure for improving the strength of a filter material for glass fiber air filter, but in the example of the patent document, although an improvement effect of tensile strength is recognized, There is a problem in that it does not improve, is not very effective in rupturing filter media during pleating or in actual use, and does not improve water repellency.
また、特許文献3の強度維持層に関する技術については、濾過層に強度維持層を接合するには特殊な設備が必要であり、また濾過層と強度層との接合面が剥離しやすく、撥水性の向上が見られない問題がある。 In addition, regarding the technology related to the strength maintaining layer of Patent Document 3, special equipment is required to join the strength maintaining layer to the filtration layer, and the joint surface between the filtration layer and the strength layer is easy to peel off, and the water repellent There is a problem that improvement is not seen.
また、本発明者らが提供した特許文献4の技術をもってしても、低坪量化による濾材の強度低下、撥水性低下を補うことは難しく、特に引裂強さの向上はあまり期待できないものであった。 Further, even with the technique of Patent Document 4 provided by the present inventors, it is difficult to compensate for the decrease in strength and water repellency of the filter medium due to the lower basis weight, and in particular, the improvement in tear strength cannot be expected so much. It was.
さらに、撥水性について、特許文献5〜8の技術があるが、これらは撥水性を有する薬品を使ってガラス繊維表面を処理したものであり、低坪量化に伴う撥水性低下を補うには大幅に薬品使用量を増やす必要があり、コストがかかるばかりか、付着量による向上効果も頭打ちになってしまう問題がある。また、薬品付着量を増やしても引裂強さの向上が見られない問題がある。 Furthermore, regarding water repellency, there are techniques of Patent Documents 5 to 8, which are obtained by treating the glass fiber surface with chemicals having water repellency, and are largely used to compensate for the decrease in water repellency associated with lower basis weight. In addition, it is necessary to increase the amount of chemical used, which is not only costly, but also has the problem that the improvement effect due to the amount of adhesion has reached its peak. In addition, there is a problem that the tear strength cannot be improved even if the chemical adhesion amount is increased.
このように、特許文献1〜8の技術はいずれも濾材の低坪量化に対する対策としては抜本的な対策ではなかった。そこで、本発明の課題は、エアフィルタ用濾材の低坪量化に伴う引裂強さと撥水性の低下問題を改善し、かつ、難燃性要望にも対応できるエアフィルタ用濾材を提供することである。 As described above, none of the techniques of Patent Documents 1 to 8 is a drastic measure as a measure for reducing the basis weight of the filter medium. Therefore, an object of the present invention is to provide a filter medium for air filter that can improve the tear strength and water repellency reduction problems associated with the reduction in the basis weight of the filter medium for air filter and can also meet the flame retardancy demand. .
本発明者らは、鋭意検討したところ、濾材の原料繊維としてガラス短繊維と繊維径5μm以下の疎水性化合繊短繊維を使用し、かつ、疎水性合成樹脂系バインダーで繊維を固定することで前記課題が解決できることを見出し、本発明を完成させた。すなわち、本発明に係る低坪量エアフィルタ用濾材は、濾材の原料繊維として、ガラス短繊維(A)と繊維径5μm以下の疎水性化合繊短繊維(B)とが質量比(A/B)で70/30〜95/5の範囲で配合されてなり、前記原料繊維100質量部に対して疎水性合成樹脂系バインダーが3〜10質量部付与されてなり、坪量が25g/m2以上50g/m2以下であることを特徴とする。 As a result of intensive studies, the present inventors have used short glass fibers and hydrophobic synthetic short fibers having a fiber diameter of 5 μm or less as raw material fibers for the filter medium, and fixing the fibers with a hydrophobic synthetic resin binder. The inventors have found that the above problems can be solved, and completed the present invention. That is, in the filter material for low basis weight air filter according to the present invention, the short glass fiber (A) and the hydrophobic synthetic fiber short fiber (B) having a fiber diameter of 5 μm or less are used as the raw material fiber of the filter medium (A / B). ) In the range of 70/30 to 95/5, 3 to 10 parts by weight of a hydrophobic synthetic resin binder is added to 100 parts by weight of the raw fiber, and the basis weight is 25 g / m 2. It is 50 g / m 2 or more.
本発明に係る低坪量エアフィルタ用濾材では、前記質量比(A/B)が78/22〜95/5の範囲であり、かつ、エアフィルタ用濾材が、空気清浄装置用ろ材燃焼性試験方法指針JACA No.11A−2003に準拠した燃焼性試験の燃焼性区分クラス3を満足することが好ましい。質量比(A/B)を78/22〜95/5の範囲とすることで、難燃性が付与される。 In the filter medium for a low basis weight air filter according to the present invention, the mass ratio (A / B) is in the range of 78/22 to 95/5, and the filter medium for the air filter is a filter medium flammability test for an air purifier. Method Guide JACA No. It is preferable to satisfy the flammability classification class 3 of the flammability test based on 11A-2003. By setting the mass ratio (A / B) in the range of 78/22 to 95/5, flame retardancy is imparted.
本発明に係る低坪量エアフィルタ用濾材では、エアフィルタ用濾材に撥水剤が付与されていることが好ましい。撥水剤の併用が可能であり、これによって、撥水性が付与される。 In the filter medium for a low basis weight air filter according to the present invention, it is preferable that a water repellent is applied to the filter medium for the air filter. A water repellent can be used in combination, thereby imparting water repellency.
本発明のエアフィルタ用濾材は、低坪量化に伴う引裂強さと撥水性の低下問題が改善されている。引裂強さについては、従来の坪量の濾材と同等の引裂強さ物性を保持している。さらに、可燃性の化合繊短繊維を配合しても、JACA No.11A−2003に準拠した難燃性を濾材に付与することができる。 The filter medium for an air filter of the present invention has improved the problems of lowering tear strength and water repellency associated with lower basis weight. About tear strength, the tear strength physical property equivalent to the filter medium of the conventional basic weight is hold | maintained. Furthermore, even if combustible synthetic short fiber is blended, JACA No. The flame retardant according to 11A-2003 can be imparted to the filter medium.
以下、本発明について実施形態を示して詳細に説明するが、本発明はこれらの記載に限定して解釈されない。本発明の効果を奏する限り、実施形態は種々の変形をしてもよい。 Hereinafter, although an embodiment is shown and explained in detail about the present invention, the present invention is limited to these descriptions and is not interpreted. As long as the effect of the present invention is exhibited, the embodiment may be variously modified.
本実施形態に係る低坪量エアフィルタ用濾材は、濾材の原料繊維として、ガラス短繊維(A)と繊維径5μm以下の疎水性化合繊短繊維(B)とが質量比(A/B)で70/30〜95/5の範囲で配合されてなり、原料繊維100質量部に対して疎水性合成樹脂系バインダーが3〜10質量部付与されてなり、坪量が25g/m2以上50g/m2以下である。 In the filter medium for a low basis weight air filter according to the present embodiment, as a raw material fiber of the filter medium, a short glass fiber (A) and a hydrophobic synthetic short fiber (B) having a fiber diameter of 5 μm or less are in a mass ratio (A / B). It is blended in the range of 70/30 to 95/5, 3 to 10 parts by weight of the hydrophobic synthetic resin binder is added to 100 parts by weight of the raw fiber, and the basis weight is 25 g / m 2 or more and 50 g. / M 2 or less.
本実施形態の坪量は、25〜50g/m2である。25g/m2未満であると、引裂強さ及び撥水性が現行坪量の濾材品質レベルより低下してしまう。また、50g/m2を超えると濾材の厚さ低減効果が薄れてしまう。なお、本発明において、現行坪量とは60〜80g/m2としている。 The basis weight of this embodiment is 25 to 50 g / m 2 . If it is less than 25 g / m 2 , the tear strength and water repellency will be lower than the filter media quality level of the current basis weight. Moreover, when it exceeds 50 g / m < 2 >, the thickness reduction effect of a filter medium will fade. In the present invention, the current basis weight is 60 to 80 g / m 2 .
本実施形態で主体繊維として使用するのはガラス短繊維と称されるものであり、ガラス短繊維は必要とされる濾過性能やその他物性に応じて、種々の繊維径を有するガラス短繊維の中から自由に選ぶことができる。特に、ガラス短繊維は、火焔延伸法やロータリー法で製造されるウール状のガラス繊維であり、濾材の圧力損失を所定の値に保ち、適正な捕集効率とするための必須成分である。繊維径が細くなるほど捕集効率は高くなるため、高性能の濾材を得るためには平均繊維径の細かい極細ガラス繊維を配合する必要がある。ただし、繊維径が細くなると圧力損失が上昇しすぎる場合があるので、この範囲内で適正な繊維径のものを選択すべきである。なお、数種の繊維径のものをブレンドして配合しても構わない。繊維径としては、概ねで5μm以下のものが使われる。ガラス組成としては、エアフィルタ用途の大半はボロシリケートガラスであり、この中には耐酸性を有するCガラスや電気絶縁性を有するEガラス(無アルカリガラス)も含まれる。また、半導体工程などにおけるボロン汚染を防止する目的で、ローボロンガラス短繊維やシリカガラス短繊維を使用することもできる。なお、本実施形態における主体繊維とは、全原料繊維配合の70質量%以上多くを占める繊維のことを示す。そして、本実施形態の場合は、ガラス短繊維のことである。 The main fiber used in this embodiment is called a glass short fiber, and the glass short fiber is a glass short fiber having various fiber diameters depending on the required filtration performance and other physical properties. You can choose freely. In particular, the short glass fiber is a wool-like glass fiber produced by a flame drawing method or a rotary method, and is an essential component for maintaining the pressure loss of the filter medium at a predetermined value and achieving an appropriate collection efficiency. As the fiber diameter becomes smaller, the collection efficiency becomes higher. Therefore, in order to obtain a high-performance filter medium, it is necessary to blend ultrafine glass fibers having a fine average fiber diameter. However, since the pressure loss may increase excessively when the fiber diameter is reduced, an appropriate fiber diameter should be selected within this range. In addition, you may blend and mix the thing of several types of fiber diameters. The fiber diameter is approximately 5 μm or less. As for the glass composition, most of the air filter applications are borosilicate glass, and this includes C glass having acid resistance and E glass (non-alkali glass) having electrical insulation. Further, for the purpose of preventing boron contamination in a semiconductor process or the like, low boron glass short fibers or silica glass short fibers can also be used. In addition, the main fiber in this embodiment shows the fiber which occupies 70 mass% or more of all the raw material fiber mixing | blending. And in the case of this embodiment, it is a short glass fiber.
本発明者らは、このガラス短繊維を主体とするエアフィルタ用濾材に関して、低坪量化に伴う引裂強さ低下及び撥水性低下についての対策を鋭意検討した結果、細径の疎水性化合繊短繊維を原料繊維の一部として適宜配合し、かつ、疎水性合成樹脂バインダーを濾材に付与することにより、引裂強さと撥水性が著しく改善されることが分かった。 As a result of diligent investigations on measures to reduce tear strength and water repellency associated with low basis weight, the present inventors have made a study on the short diameter hydrophobic synthetic fiber shorts. It has been found that the tear strength and water repellency are remarkably improved by appropriately blending the fibers as part of the raw fibers and adding a hydrophobic synthetic resin binder to the filter medium.
疎水性化合繊短繊維は、湿式紡糸法、乾式紡糸法、エマルジョン紡糸法、溶融紡糸法などの紡糸法により、紡糸液を紡糸口金から紡糸した糸状繊維を適宜の長さにカットしたもので、不織布の原料や布団綿などさまざまな用途に使用されるものである。このうち、本実施形態で使用される疎水性化合繊短繊維は、繊維径5μm以下の細径でなければならない。繊維径が5μmより太いと、引裂強さの改善効果はあまりない。疎水性化合繊短繊維の繊維長は、好ましくは1mm以上20mm以下、更に好ましくは3mm以上10mm以下である。20mmより長いと、シート作製時の繊維分散工程で繊維が未分散を起こしやすくなり、出来上がった濾材シートが不均一となって、捕集性能の低下を引き起こす場合がある。また、1mmより短いと、引裂強さの改善効果が低くなる場合がある。 Hydrophobic synthetic fiber short fiber is a fiber-like fiber obtained by spinning a spinning solution from a spinneret by a spinning method such as a wet spinning method, a dry spinning method, an emulsion spinning method, or a melt spinning method. It is used for various purposes such as raw materials for nonwoven fabrics and futon cotton. Among these, the hydrophobic synthetic short fibers used in this embodiment must have a small diameter of 5 μm or less. If the fiber diameter is thicker than 5 μm, there is not much effect of improving the tear strength. The fiber length of the hydrophobic synthetic short fiber is preferably 1 mm or more and 20 mm or less, more preferably 3 mm or more and 10 mm or less. If it is longer than 20 mm, the fibers are likely to be non-dispersed in the fiber dispersion step at the time of producing the sheet, and the completed filter medium sheet becomes non-uniform, which may cause a decrease in the collection performance. Moreover, when shorter than 1 mm, the improvement effect of tear strength may become low.
疎水性化合繊短繊維の組成としては、ポリエステル繊維、アクリル繊維、ポリエチレン繊維、ポリプロピレン繊維など挙げられるが、疎水性であれば特に限定されるものではない。組成としては、これらのほかに前記の紡糸法に更に改良を加えて細径化した海島型繊維、分割型繊維、更に化合繊に機械的処理を加えてパルプ状にしたタイプのものも使用できる。また、これらの繊維を適宜併用してもよい。これに対し、親水性であるビニロン繊維、半合成繊維のレーヨン繊維、セルロース系繊維などは、濾材の引裂強さの向上効果が無いうえ、撥水性の向上を阻害するため好ましくない。 Examples of the composition of the hydrophobic synthetic short fiber include polyester fiber, acrylic fiber, polyethylene fiber, and polypropylene fiber, but are not particularly limited as long as it is hydrophobic. In addition to these, sea island-type fibers, split-type fibers, which have been further refined by the above spinning method, and pulp-types obtained by adding mechanical treatment to synthetic fibers can also be used. . Moreover, you may use these fibers together suitably. In contrast, hydrophilic vinylon fibers, semi-synthetic rayon fibers, cellulosic fibers, and the like are not preferable because they do not have an effect of improving the tear strength of the filter medium and hinder the improvement of water repellency.
また、ガラス繊維主体のエアフィルタ用濾材は、通常、大部分が無機質材料で構成されているため、空気清浄装置用ろ材燃焼性試験方法指針JACA No.11A−2003に準拠した難燃性を有している。しかし、濾材構成に可燃性である疎水性化合繊短繊維を配合することは、同試験方法の難燃性を満たさなくなることが懸念される。難燃性については濾材使用目的で要求度が異なるので、必ずしも必要な特性とはいえないが、難燃性が要求される場合に対応できなくなる可能性がある。方法の一つとしては化合繊短繊維自体を難燃化させる方法が挙げられるが、難燃化には環境上好ましくないハロゲン及び/又は半導体製造工程で歩留まりを低下させるリンなどを付加する必要があり、あまり好ましくない。そこで、本発明者らが鋭意検討した結果、細径の疎水性化合繊短繊維の配合率を制御することで、必ずしも化合繊自体が難燃性である必要がないことがわかった。 Further, since the filter medium for air filter mainly composed of glass fiber is usually composed of an inorganic material, the filter medium flammability test method guideline JACA No. It has flame retardancy according to 11A-2003. However, there is a concern that blending a combustible hydrophobic synthetic fiber short fiber into the filter medium structure will not satisfy the flame retardancy of the test method. Since the degree of demand for flame retardancy varies depending on the purpose of use of the filter medium, it is not necessarily a necessary characteristic, but there is a possibility that it may not be possible when flame retardancy is required. One of the methods is a method of flame retarding the synthetic short fiber itself, but it is necessary to add environmentally unfavorable halogen and / or phosphorus which lowers the yield in the semiconductor manufacturing process. Yes, not very desirable. Thus, as a result of intensive studies by the present inventors, it has been found that the synthetic fiber itself does not necessarily need to be flame-retardant by controlling the blending ratio of the small-diameter hydrophobic synthetic synthetic short fiber.
ガラス短繊維(A)と疎水性化合繊短繊維(B)との配合比は、質量比(A/B)で70/30〜95/5とする。また、濾材に難燃性を付加させるために好ましくは質量比(A/B)で78/22〜95/5とする。ガラス短繊維(A)と疎水性化合繊短繊維(B)における疎水性化合繊短繊維(B)の配合率が5質量%未満であると、濾材の引裂強さと撥水性の向上効果が薄れてしまう。また、30質量%を超えると、疎水性化合繊短繊維が濾材シートを構成するガラス短繊維のネットワークを乱してしまい、濾材の捕集性能が低下してしまう。また、ガラス短繊維(A)と疎水性化合繊短繊維(B)における疎水性化合繊短繊維(B)の配合率が22質量%を超えると濾材が難燃性を失い、JACA No.11A−2003試験方法の区分クラス3を満たさなくなる。 The compounding ratio of the short glass fiber (A) and the hydrophobic synthetic short fiber (B) is 70/30 to 95/5 in mass ratio (A / B). Further, in order to add flame retardancy to the filter medium, the mass ratio (A / B) is preferably 78/22 to 95/5. When the blending ratio of the hydrophobic synthetic fiber staple fiber (B) in the short glass fiber (A) and the hydrophobic synthetic fiber staple fiber (B) is less than 5% by mass, the effect of improving the tear strength and water repellency of the filter medium is reduced. End up. Moreover, when it exceeds 30 mass%, the hydrophobic synthetic fiber short fiber will disturb the network of the glass short fiber which comprises a filter-medium sheet | seat, and the collection performance of a filter medium will fall. Further, when the blending ratio of the hydrophobic synthetic short fiber (B) in the short glass fiber (A) and the hydrophobic synthetic short fiber (B) exceeds 22% by mass, the filter medium loses flame retardancy. The classification class 3 of the 11A-2003 test method is not satisfied.
また、本実施形態の目的に支障が無い限り、副資材として、ガラス短繊維より太い5μm以上の繊維径を有するチョップドガラス繊維、無機繊維、太径の天然繊維、太径の化合繊短繊維などを、主体繊維の配合の中で、15質量%以下の配合をしても差し支えない。 In addition, as long as there is no hindrance to the object of the present embodiment, as a secondary material, chopped glass fiber having a fiber diameter of 5 μm or more thicker than short glass fiber, inorganic fiber, large natural fiber, thick synthetic fiber short fiber, etc. May be blended in an amount of 15% by mass or less in the blend of the main fiber.
本実施形態の効果を発揮させるためには、濾材に更に疎水性合成樹脂系バインダーを付与することが必要である。これらバインダーは、水溶液又は水系エマルジョンの形のもの、すなわち、バインダー液として濾材に付与される。疎水性合成樹脂系バインダーとしては、アクリル酸エステル系樹脂、ウレタン系樹脂、エポキシ系樹脂、オレフィン系樹脂などが挙げられる。一方、親水性バインダーである澱粉、ポリビニルアルコール系樹脂などは、濾材の引裂強さの向上効果が無いうえ、撥水性の向上を阻害するため好ましくない。ただし、本実施形態の目的に支障が無い限り、疎水性合成樹脂系バインダーに加えて副資材として必要最低限量の親水性バインダーを付与することは差し支えない。同時に、これらバインダーは、繊維自体に自己接着能のないガラス短繊維同士を接着させる効果もある。疎水性合成樹脂系バインダーの付与量としては、原料繊維100質量部に対して好ましくは3〜10質量部であり、更に好ましくは4〜7質量部である。3質量部未満であると本実施形態の効果は発揮されず、10質量部を超えるとバインダーの樹脂膜が濾材の繊維ネットワークの孔を塞ぐため、濾材の圧力損失を増大させるなどの問題が生じる。 In order to exert the effect of this embodiment, it is necessary to further add a hydrophobic synthetic resin binder to the filter medium. These binders are applied to the filter medium in the form of an aqueous solution or an aqueous emulsion, that is, as a binder liquid. Examples of the hydrophobic synthetic resin binder include acrylic ester resins, urethane resins, epoxy resins, and olefin resins. On the other hand, starch, polyvinyl alcohol resin, and the like, which are hydrophilic binders, are not preferable because they do not have the effect of improving the tear strength of the filter medium and inhibit the improvement of water repellency. However, as long as the purpose of the present embodiment is not hindered, it is possible to provide a minimum amount of hydrophilic binder as a secondary material in addition to the hydrophobic synthetic resin binder. At the same time, these binders also have an effect of bonding short glass fibers having no self-adhesive ability to the fibers themselves. The applied amount of the hydrophobic synthetic resin binder is preferably 3 to 10 parts by mass, and more preferably 4 to 7 parts by mass with respect to 100 parts by mass of the raw fiber. If the amount is less than 3 parts by mass, the effect of the present embodiment is not exhibited. If the amount exceeds 10 parts by mass, the resin film of the binder closes the pores of the fiber network of the filter medium, thereby causing problems such as increasing the pressure loss of the filter medium. .
さらに、濾材に実用上必要とされる撥水性を付与するために、ほとんどの場合、撥水剤が付与される。これら撥水剤も、一般的に、バインダーと同様に、バインダー液と混合するか、単独で濾材に付与される。撥水剤としては、シリコーン系樹脂、フッ素系樹脂、ワックス、アルキルケテンダイマーなどが用いられる。 Furthermore, in order to provide the filter medium with water repellency that is practically required, a water repellent is provided in most cases. These water repellents are also generally mixed with a binder liquid or applied alone to the filter medium in the same manner as the binder. As the water repellent, silicone resin, fluorine resin, wax, alkyl ketene dimer and the like are used.
バインダー液には、その他必要に応じて界面活性剤、消泡剤、pH調整剤、湿潤剤、保水剤、増粘剤、架橋剤、離型剤、防腐剤、柔軟剤、帯電防止剤、耐水化剤、可塑剤、蛍光増白剤、着色顔料、着色染料、紫外線吸収剤、酸化防止剤、香料、脱臭剤等の添加剤を適宜選定して添加することができる。 For binder liquids, surfactants, antifoaming agents, pH adjusters, wetting agents, water retention agents, thickeners, cross-linking agents, mold release agents, preservatives, softeners, antistatic agents, water resistance Additives such as an agent, a plasticizer, a fluorescent brightening agent, a coloring pigment, a coloring dye, an ultraviolet absorber, an antioxidant, a fragrance, and a deodorizing agent can be appropriately selected and added.
本実施形態の構成のうち、疎水性化合繊短繊維と疎水性合成樹脂系バインダーのいずれが欠けても本発明の効果は発揮できない。この理由としては、疎水性化合繊短繊維と疎水性合成樹脂系バインダーがいずれも疎水性のため繊維と樹脂系バインダーの相溶性が良いのでよく接着し、またガラス短繊維と樹脂系バインダー(疎水性合成樹脂系バインダー)も接着しているため、引裂強さに対し大きな効果を発揮していると推定される。加えて、疎水性化合繊短繊維が、繊維径5μm以下と細径であり、また、比表面積が大きいことから、ガラス短繊維−細径疎水性化合繊短繊維−疎水性合成樹脂系バインダー間の強固な接着を促進していると考えられる。撥水性の向上効果については、化合繊短繊維が細径かつ疎水性であるため、水の浸透性を強く阻害していると推定される。これは、通常の化合繊には見られない現象である。疎水性合成樹脂系バインダーを増やせば同様の効果が出るが、前述のとおりバインダーの樹脂膜が濾材の繊維ネットワークの孔を塞ぐため、問題が生じる。細径疎水性化合繊短繊維は、繊維状であるため、このような問題を生じない。 Among the configurations of the present embodiment, the effects of the present invention cannot be exhibited even if either the hydrophobic synthetic fiber short fiber or the hydrophobic synthetic resin binder is missing. This is because the hydrophobic synthetic fiber short fiber and the hydrophobic synthetic resin-based binder are both hydrophobic, so the fibers and the resin-based binder have good compatibility, and the glass short fiber and the resin-based binder (hydrophobic) It is presumed that it has a great effect on the tear strength. In addition, since the hydrophobic synthetic synthetic short fiber has a small fiber diameter of 5 μm or less and a large specific surface area, it is between the short glass fiber, the small hydrophobic synthetic synthetic fiber, and the hydrophobic synthetic resin binder. It is thought that it promotes strong adhesion. With regard to the effect of improving water repellency, it is presumed that the synthetic fiber short fibers are thin and hydrophobic, and thus strongly impede water permeability. This is a phenomenon that is not seen in ordinary synthetic fibers. If the hydrophobic synthetic resin binder is increased, the same effect can be obtained, but a problem arises because the resin film of the binder plugs the pores of the fiber network of the filter medium as described above. Since the small-diameter hydrophobic synthetic short fiber is fibrous, such a problem does not occur.
濾材の製造工程では、繊維を水中に分散したのち、抄紙ワイヤ上に繊維を積層し、ワイヤ下方から脱水してシートを形成する、いわゆる湿式抄紙法が用いられる。このとき用いる抄紙機の種類は、本実施形態では限定されず、例えば枚葉式抄紙装置、又は連続抄紙機であれば長網式抄紙機、円網式抄紙機、傾斜ワイヤ式抄紙機、ギャップフォーマー、デルタフォーマーなどを用いることができ、それら一種以上を組み合わせた多層抄き抄紙機を用いてもよい。このとき、より高性能なフィルタ用濾材を得るためには、できるだけ均一に、地合良く、嵩高くシート化することが望ましい。 In the manufacturing process of the filter medium, a so-called wet papermaking method is used, in which fibers are dispersed in water, then the fibers are laminated on a papermaking wire, and dehydrated from below the wire to form a sheet. The type of the paper machine used at this time is not limited in this embodiment. For example, if it is a sheet type paper machine, or a continuous paper machine, a long net type paper machine, a circular net type paper machine, an inclined wire type paper machine, a gap A former, a delta former or the like can be used, and a multilayer paper machine combining one or more of them may be used. At this time, in order to obtain a filter medium with higher performance, it is desirable to form the sheet as uniformly as possible, with a good texture, and with a high bulk.
次に、シート化された繊維ウェブにバインダー成分を付与する工程となる。バインダーの付与方法としては、各種のバインダー成分を水などの溶媒に稀釈したバインダー液を、含浸、ロールアプリケート、スプレー、カーテン塗工などの各種の方法でシートに付与したのち、余分なバインダー液を負圧又は正圧の空気で除去する方法が一般的である。バインダー液を付与する前のシートは、湿潤状態であっても乾燥状態であっても構わないが、より高性能なフィルタ濾材を得るためには、シートは湿潤又は半湿潤状態であることが望ましい。 Next, it becomes the process of providing a binder component to the fiber web formed into a sheet. As a method for applying the binder, a binder solution obtained by diluting various binder components in a solvent such as water is applied to the sheet by various methods such as impregnation, roll application, spraying, curtain coating, etc., and then an excess binder solution. Is generally removed by negative pressure or positive pressure air. The sheet before applying the binder liquid may be in a wet state or in a dry state, but in order to obtain a filter medium with higher performance, the sheet is preferably in a wet or semi-moist state. .
バインダー液を付与した後のシートは、乾燥ゾーンで乾燥される。このときの乾燥方法は、特に限定されないが、熱風乾燥、ドラム乾燥、赤外線乾燥などが好適に用いられる。乾燥温度としては110〜150℃が望ましい。 The sheet after applying the binder liquid is dried in a drying zone. The drying method at this time is not particularly limited, but hot air drying, drum drying, infrared drying and the like are preferably used. The drying temperature is preferably 110 to 150 ° C.
完成したシートは、オンライン又はオフラインによって巻き取られ、又はカッターによって裁断されて製品となる。 The completed sheet is wound up online or offline, or cut by a cutter to become a product.
次に、実施例を挙げて本発明をより具体的に説明するが、本発明はこれら実施例に限定されるものではない。また、例中の「部」及び「%」は、特に断らない限り「質量部」及び「質量%」を示す。 Next, the present invention will be described more specifically with reference to examples. However, the present invention is not limited to these examples. Further, “parts” and “%” in the examples indicate “parts by mass” and “% by mass” unless otherwise specified.
(実施例1)
平均繊維径2.5μm以下のボロシリケートガラス短繊維(ジョンズマンビル社製、Micro−Strand(登録商標)Fiber Glass Micro−Fibers Type 475)90質量%、繊維径0.1dtex(推定繊維径3.0μm)、繊維長3mmのポリエステル短繊維(帝人ファイバー社製、TM04PN)10質量%に硫酸酸性pH3.5の酸性水を加えて濃度0.5%とし、これら原料を食品用ミキサー(松下電器産業社製;品番MX‐V200)内で1分間離解した。次いで、離解後の原料を同じ酸性水で濃度0.1%まで希釈し、手抄装置を用いて抄紙することによって湿紙を得た。次にアクリル系ラテックス(商品名:ボンコートAN−155−E、製造元:DIC(株))、フッ素系撥水剤(商品名:NKガードNDN−9E、製造元:日華化学(株))を、アクリル系ラテックス/フッ素系撥水剤の固形分質量比率が100/8となるように混合した撥水剤含有バインダー液を、湿紙に対して含浸付与し、その後130℃のロールドライヤーで乾燥し、坪量40g/m2、バインダー付与率が対濾材5.0質量%であるHEPA濾材を得た。ここで、平均繊維径2.5μm以下のボロシリケートガラス短繊維とは、目的の圧力損失(実施例では275Pa)とするため平均繊維径2.5μm以下の各種繊維径のボロシリケートガラス短繊維を適宜組み合わせたものであり、以下の実施例も同様である。
Example 1
Short borosilicate glass fibers having an average fiber diameter of 2.5 μm or less (manufactured by Johns Manville, Micro-Strand (registered trademark) Fiber Glass Micro-Fibers Type 475), 90 mass%, fiber diameter of 0.1 dtex (estimated fiber diameter of 3. 0 μm), polyester short fiber with a fiber length of 3 mm (TM04PN, manufactured by Teijin Fibers Ltd.) is added to 10% by mass of acidic water having a sulfuric acid pH of 3.5 to make the concentration 0.5%. The product was disaggregated for 1 minute in a product number MX-V200). Subsequently, the wet raw paper was obtained by diluting the raw material after disaggregation with the same acidic water to a concentration of 0.1% and making paper using a hand-making apparatus. Next, acrylic latex (trade name: Boncourt AN-155-E, manufacturer: DIC Corporation), fluorine-based water repellent (trade name: NK Guard NDN-9E, manufacturer: Nikka Chemical Co., Ltd.), Impregnating the wet paper with a water repellent-containing binder liquid mixed so that the solid mass ratio of acrylic latex / fluorine water repellent is 100/8, and then drying with a roll dryer at 130 ° C. A HEPA filter medium having a basis weight of 40 g / m 2 and a binder application rate of 5.0% by mass with respect to the filter medium was obtained. Here, borosilicate glass short fibers having an average fiber diameter of 2.5 μm or less are borosilicate glass short fibers having various fiber diameters having an average fiber diameter of 2.5 μm or less in order to obtain a target pressure loss (275 Pa in the examples). These are combined as appropriate, and the following examples are also the same.
(実施例2)
実施例1において、繊維配合を平均繊維径2.5μm以下のボロシリケートガラス短繊維80質量%、繊維径0.1dtex(推定繊維径3.0μm)、繊維長3mmのポリエステル短繊維20質量%とした以外は、実施例1と同様にして坪量25g/m2、バインダー付与率が対濾材5.0質量%であるHEPA濾材を得た。
(Example 2)
In Example 1, the fiber composition is 80% by mass of short borosilicate glass fibers having an average fiber diameter of 2.5 μm or less, a fiber diameter of 0.1 dtex (estimated fiber diameter of 3.0 μm), and 20% by mass of polyester short fibers having a fiber length of 3 mm. A HEPA filter medium having a basis weight of 25 g / m 2 and a binder application rate of 5.0% by mass with respect to the filter medium was obtained in the same manner as in Example 1.
(実施例3)
実施例1において、繊維配合を平均繊維径2.5μm以下のボロシリケートガラス短繊維75質量%、繊維径0.1dtex(推定繊維径3.0μm)、繊維長3mmのポリエステル短繊維25質量%とした以外は、実施例1と同様にして坪量25g/m2、バインダー付与率が対濾材5.0質量%であるHEPA濾材を得た。
(Example 3)
In Example 1, the fiber composition was 75% by mass of short borosilicate glass fibers having an average fiber diameter of 2.5 μm or less, a fiber diameter of 0.1 dtex (estimated fiber diameter of 3.0 μm), and 25% by mass of polyester short fibers having a fiber length of 3 mm. A HEPA filter medium having a basis weight of 25 g / m 2 and a binder application rate of 5.0% by mass with respect to the filter medium was obtained in the same manner as in Example 1.
(実施例4)
実施例1において、繊維配合を平均繊維径2.5μm以下のボロシリケートガラス短繊維85質量%、繊維径0.2dtex(推定繊維径4.3μm)、繊維長3mmのポリエステル短繊維(帝人ファイバー社製、TK08PN)15質量%とした以外は、実施例1と同様にして坪量40g/m2、バインダー付与率が対濾材5.0質量%であるHEPA濾材を得た。
Example 4
In Example 1, the fiber composition was 85% by mass of borosilicate glass short fibers having an average fiber diameter of 2.5 μm or less, a fiber diameter of 0.2 dtex (estimated fiber diameter 4.3 μm), and a polyester short fiber having a fiber length of 3 mm (Teijin Fibers Limited). HTK filter medium having a basis weight of 40 g / m 2 and a binder application rate of 5.0% by mass with respect to the filter medium was obtained in the same manner as in Example 1 except that the amount was 15% by mass.
(実施例5)
実施例1において、繊維配合を平均繊維径2.5μm以下のボロシリケートガラス短繊維90質量%、繊維径0.1dtex(推定繊維径3.3μm)、繊維長3mmのアクリル短繊維(三菱レーヨン社製、D122)10質量%とした以外は、実施例1と同様にして坪量40g/m2、バインダー付与率が対濾材5.0質量%であるHEPA濾材を得た。
(Example 5)
In Example 1, an acrylic short fiber (Mitsubishi Rayon Co., Ltd.) having a fiber composition of 90% by mass of borosilicate short glass fibers having an average fiber diameter of 2.5 μm or less, a fiber diameter of 0.1 dtex (estimated fiber diameter of 3.3 μm), and a fiber length of 3 mm. D122) A HEPA filter medium having a basis weight of 40 g / m 2 and a binder application rate of 5.0% by mass with respect to the filter medium was obtained in the same manner as in Example 1 except that the content was changed to 10% by mass.
(実施例6)
実施例1において、繊維配合を平均繊維径2.5μm以下のボロシリケートガラス短繊維93質量%、繊維径0.06dtex(推定繊維径2.6μm)、繊維長3mmのアクリル短繊維(三菱レーヨン社製、開発品)7質量%とした以外は、実施例1と同様にして坪量40g/m2、バインダー付与率が対濾材5.0質量%であるHEPA濾材を得た。
(Example 6)
In Example 1, an acrylic short fiber (Mitsubishi Rayon Co., Ltd.) having a fiber composition of 93% by mass of borosilicate glass short fibers having an average fiber diameter of 2.5 μm or less, a fiber diameter of 0.06 dtex (estimated fiber diameter of 2.6 μm), and a fiber length of 3 mm. (Manufactured, developed product) A HEPA filter medium having a basis weight of 40 g / m 2 and a binder application rate of 5.0 mass% with respect to the filter medium was obtained in the same manner as in Example 1 except that the content was 7 mass%.
(実施例7)
実施例1において、繊維配合を平均繊維径2.5μm以下のボロシリケートガラス短繊維95質量%、繊維径0.1dtex(推定繊維径3.3μm)、繊維長3mmのアクリル短繊維5質量%とした以外は、実施例1と同様にして坪量50g/m2、バインダー付与率が対濾材5.0質量%であるHEPA濾材を得た。
(Example 7)
In Example 1, the fiber blending was 95% by mass of borosilicate glass short fibers having an average fiber diameter of 2.5 μm or less, a fiber diameter of 0.1 dtex (estimated fiber diameter of 3.3 μm), and 5% by mass of acrylic short fibers having a fiber length of 3 mm. A HEPA filter medium having a basis weight of 50 g / m 2 and a binder application rate of 5.0% by mass with respect to the filter medium was obtained in the same manner as in Example 1.
(実施例8)
実施例1において、繊維配合を平均繊維径2.5μm以下のボロシリケートガラス短繊維70質量%、繊維径0.1dtex(推定繊維径3.0μm)、繊維長3mmのポリエステル短繊維30質量%とした以外は、実施例1と同様にして坪量40g/m2、バインダー付与率が対濾材5.0質量%であるHEPA濾材を得た。
(Example 8)
In Example 1, the fiber composition was 70% by mass of short borosilicate glass fibers having an average fiber diameter of 2.5 μm or less, a fiber diameter of 0.1 dtex (estimated fiber diameter of 3.0 μm), and 30% by mass of polyester short fibers having a fiber length of 3 mm. A HEPA filter medium having a basis weight of 40 g / m 2 and a binder application rate of 5.0% by mass with respect to the filter medium was obtained in the same manner as in Example 1.
(実施例9)
実施例1において、繊維配合を平均繊維径2.5μm以下のボロシリケートガラス短繊維78質量%、繊維径0.1dtex(推定繊維径3.0μm)、繊維長3mmのポリエステル短繊維22質量%とした以外は、実施例1と同様にして坪量25g/m2、バインダー付与率が対濾材5.0質量%であるHEPA濾材を得た。
Example 9
In Example 1, the fiber composition was 78% by mass of borosilicate short glass fibers having an average fiber diameter of 2.5 μm or less, a fiber diameter of 0.1 dtex (estimated fiber diameter of 3.0 μm), and 22% by mass of polyester short fibers having a fiber length of 3 mm. A HEPA filter medium having a basis weight of 25 g / m 2 and a binder application rate of 5.0% by mass with respect to the filter medium was obtained in the same manner as in Example 1.
(実施例10)
実施例4において、バインダー付与率を対濾材3.0質量%とした以外は、実施例4と同様にして坪量40g/m2であるHEPA濾材を得た。
(Example 10)
In Example 4, a HEPA filter medium having a basis weight of 40 g / m 2 was obtained in the same manner as in Example 4 except that the binder application rate was 3.0% by mass with respect to the filter medium.
(実施例11)
実施例4において、バインダー付与率を対濾材10.0質量%とした以外は、実施例4と同様にして坪量40g/m2であるHEPA濾材を得た。
(Example 11)
In Example 4, a HEPA filter medium having a basis weight of 40 g / m 2 was obtained in the same manner as in Example 4 except that the binder application rate was 10.0% by mass with respect to the filter medium.
(比較例1)
実施例1において、繊維配合を平均繊維径2.5μm以下のボロシリケートガラス短繊維100質量%以外は、実施例1と同様にして坪量80g/m2、バインダー付与率が対濾材5.0質量%であるHEPA濾材を得た。
(Comparative Example 1)
In Example 1, the basis weight was 80 g / m 2 , and the binder application rate was 5.0 with respect to the filter medium except that the fiber composition was 100% by mass of short borosilicate glass fibers having an average fiber diameter of 2.5 μm or less. A HEPA filter medium having a mass% was obtained.
(比較例2)
実施例1において、繊維配合を平均繊維径2.5μm以下のボロシリケートガラス短繊維100質量%以外は、実施例1と同様にして坪量40g/m2、バインダー付与率が対濾材5.0質量%であるHEPA濾材を得た。
(Comparative Example 2)
In Example 1, the basis weight was 40 g / m 2 , and the binder application rate was 5.0 with respect to the filter medium, except that the fiber composition was 100% by mass of short borosilicate glass fibers having an average fiber diameter of 2.5 μm or less. A HEPA filter medium having a mass% was obtained.
(比較例3)
実施例1において、繊維配合を平均繊維径2.5μm以下のボロシリケートガラス短繊維90質量%、繊維径1.7dtex(推定繊維径12.5μm)、繊維長3mmのポリエステル短繊維(帝人ファイバー社製、TT04N)10質量%とした以外は、実施例1と同様にして坪量40g/m2、バインダー付与率が対濾材5.0質量%であるHEPA濾材を得た。
(Comparative Example 3)
In Example 1, 90% by mass of borosilicate short glass fibers having an average fiber diameter of 2.5 μm or less, a fiber diameter of 1.7 dtex (estimated fiber diameter of 12.5 μm), and a short polyester fiber having a fiber length of 3 mm (Teijin Fibers Ltd.) HTT filter medium having a basis weight of 40 g / m 2 and a binder application rate of 5.0% by mass with respect to the filter medium was obtained in the same manner as in Example 1 except that the amount was 10% by mass.
(比較例4)
実施例1において、繊維配合を平均繊維径2.5μm以下のボロシリケートガラス短繊維90質量%、繊維径0.6dtex(推定繊維径7.4μm)、繊維長5mmのポリエステル短繊維(帝人ファイバー社製、TA04N)10質量%とした以外は、実施例1と同様にして坪量40g/m2、バインダー付与率が対濾材5.0質量%であるHEPA濾材を得た。
(Comparative Example 4)
In Example 1, the blend of fibers was 90% by mass of short borosilicate glass fibers having an average fiber diameter of 2.5 μm or less, a fiber diameter of 0.6 dtex (estimated fiber diameter of 7.4 μm), and a polyester short fiber having a fiber length of 5 mm (Teijin Fibers Limited). HEPA filter medium having a basis weight of 40 g / m 2 and a binder application rate of 5.0% by mass with respect to the filter medium was obtained in the same manner as in Example 1 except that the amount was 10% by mass.
(比較例5)
実施例1において、繊維配合を平均繊維径2.5μm以下のボロシリケートガラス短繊維97質量%、繊維径0.1dtex(推定繊維径3.3μm)、繊維長3mmのアクリル短繊維3質量%とした以外は、実施例1と同様にして坪量50g/m2、バインダー付与率が対濾材5.0質量%であるHEPA濾材を得た。
(Comparative Example 5)
In Example 1, the fiber blending was 97% by mass of borosilicate glass short fibers having an average fiber diameter of 2.5 μm or less, a fiber diameter of 0.1 dtex (estimated fiber diameter of 3.3 μm), and 3% by mass of acrylic short fibers having a fiber length of 3 mm. A HEPA filter medium having a basis weight of 50 g / m 2 and a binder application rate of 5.0% by mass with respect to the filter medium was obtained in the same manner as in Example 1.
(比較例6)
実施例1において、繊維配合を平均繊維径2.5μm以下のボロシリケートガラス短繊維65質量%、繊維径0.1dtex(推定繊維径3.3μm)、繊維長3mmのアクリル短繊維35質量%とした以外は、実施例1と同様にして坪量40g/m2、バインダー付与率が対濾材5.0質量%であるHEPA濾材を得た。
(Comparative Example 6)
In Example 1, the fiber composition was 65% by mass of borosilicate glass short fibers having an average fiber diameter of 2.5 μm or less, a fiber diameter of 0.1 dtex (estimated fiber diameter of 3.3 μm), and 35% by mass of acrylic short fibers having a fiber length of 3 mm. A HEPA filter medium having a basis weight of 40 g / m 2 and a binder application rate of 5.0% by mass with respect to the filter medium was obtained in the same manner as in Example 1.
(比較例7)
平均繊維径2.5μm以下のボロシリケートガラス短繊維90質量%、繊維径0.1dtex(推定繊維径3.3μm)、繊維長3mmのアクリル短繊維10質量%、PVAバインダー繊維(フィブリボンド 三晶社製、No.243)対濾材4質量%に硫酸酸性pH3.5の酸性水を加えて濃度0.5%とし、これら原料を食品用ミキサー(松下電器産業社製;品番MX‐V200)内で1分間離解した。次いで、離解後の原料を同じ酸性水で濃度0.1%まで希釈し、手抄装置を用いて抄紙することによって湿紙を得た。次に、フッ素系撥水剤(商品名:NKガードNDN−9E、製造元:日華化学(株))だけの含浸液を湿紙に対して対濾材付与率0.4質量%となるように含浸付与し、その後130℃のロールドライヤーで乾燥し、坪量40g/m2、バインダー付与率が対濾材4.4質量%であるHEPA濾材を得た。
(Comparative Example 7)
90% by mass of short borosilicate glass fibers having an average fiber diameter of 2.5 μm or less, a fiber diameter of 0.1 dtex (estimated fiber diameter of 3.3 μm), 10% by mass of acrylic short fibers with a fiber length of 3 mm, PVA binder fiber (fibril bond tricrystal No. 243) to 4% by mass of filter medium with acid water of sulfuric acid pH 3.5 added to a concentration of 0.5%, and these raw materials are mixed in a food mixer (Matsushita Electric Industrial Co., Ltd .; product number MX-V200) And disaggregated for 1 minute. Subsequently, the wet raw paper was obtained by diluting the raw material after disaggregation with the same acidic water to a concentration of 0.1% and making paper using a hand-making apparatus. Next, an impregnating liquid containing only a fluorine-based water repellent (trade name: NK GUARD NDN-9E, manufacturer: Nikka Chemical Co., Ltd.) is applied to the wet paper so that the application rate of the filter medium is 0.4% by mass. Impregnation was applied and then dried with a roll dryer at 130 ° C. to obtain a HEPA filter medium having a basis weight of 40 g / m 2 and a binder application rate of 4.4% by mass with respect to the filter medium.
(比較例8)
比較例7において、繊維配合を平均繊維径2.5μm以下のボロシリケートガラス短繊維90質量%、繊維径0.6dtex(推定繊維径7.7μm)、繊維長3mmのビニロン短繊維(クラレ社製、VPB053)10質量%とした以外は、比較例7と同様にして坪量40g/m2、バインダー付与率が対濾材4.4質量%であるHEPA濾材を得た。
(Comparative Example 8)
In Comparative Example 7, the fiber composition was 90% by mass of borosilicate glass short fibers having an average fiber diameter of 2.5 μm or less, a fiber diameter of 0.6 dtex (estimated fiber diameter of 7.7 μm), and a vinylon short fiber having a fiber length of 3 mm (manufactured by Kuraray Co., Ltd.). , VPB053) A HEPA filter medium having a basis weight of 40 g / m 2 and a binder application rate of 4.4 mass% with respect to the filter medium was obtained in the same manner as in Comparative Example 7 except that the content was 10% by mass.
(比較例9)
実施例4において、バインダー付与率を対濾材2.0質量%とした以外は、実施例4と同様にして坪量40g/m2であるHEPA濾材を得た。
(Comparative Example 9)
In Example 4, a HEPA filter medium having a basis weight of 40 g / m 2 was obtained in the same manner as in Example 4 except that the binder application rate was 2.0% by mass with respect to the filter medium.
(比較例10)
実施例4において、バインダー付与率を対濾材11.0質量%とした以外は、実施例4と同様にして坪量40g/m2であるHEPA濾材を得た。
(Comparative Example 10)
In Example 4, a HEPA filter medium having a basis weight of 40 g / m 2 was obtained in the same manner as in Example 4 except that the binder application rate was 11.0% by mass with respect to the filter medium.
実施例及び比較例の濾材について次の試験を行った。
(1)圧力損失
自製の装置を用いて、有効面積100cm2の濾材に面風速5.3cm/secで通風したときの圧力損失を微差圧計で測定した。
(2)0.3−0.4μmDOP透過率
ラスキンノズルで発生させた多分散DOP粒子を含む空気を、有効面積100cm2の濾材に面風速5.3cm/secで通風したときの上流及び下流の個数比からDOPの透過率を、リオン社製レーザーパーティクルカウンターを使用して測定した。なお、対象粒径は、0.3−0.4μmとした。
(3)PF値
濾材のフィルタ性能の指標となるPF値は、(1)、(2)のデータを使って次式数1から求めた。PF値が高いほど、同一圧力損失で低透過率又は同一透過率で低圧力損失を示す。
濾材から長さ63mm、幅76mmの試験片を採取し、これを5枚重ね合わせてエルメンドルフ形引裂試験機自動デジタル式(熊谷理機工業)を用いて測定を行った。また、比引裂強さは、引裂強さを坪量で除することによって求めた。
(5)引張強さ
濾材から1インチ幅×130mm長にカットした試験片を採取し、スパン長100mm、引張速度15mm/分で定速引張試験機(東洋精機製作所;ストログラフM1)を用いて測定した。
(6)撥水性
撥水性は、MIL‐STD‐282に準拠して測定した。
(7)難燃性
難燃性は、空気清浄装置用ろ材燃焼性試験方法指針JACA No.11A−2003に準拠した燃焼性試験器(スガ試験機械;UL‐94HBF)で測定した。評価は、燃焼性区分クラス3を満足するものを○、これ以外を×とした。
The following tests were conducted on the filter media of Examples and Comparative Examples.
(1) Pressure loss Using a self-manufactured device, the pressure loss was measured with a micro differential pressure gauge when air was passed through a filter medium having an effective area of 100 cm 2 at a surface wind speed of 5.3 cm / sec.
(2) 0.3-0.4 μm DOP permeability Upstream and downstream when air containing polydisperse DOP particles generated by a Ruskin nozzle is passed through a filter medium having an effective area of 100 cm 2 at a surface wind speed of 5.3 cm / sec. From the number ratio, the transmittance of DOP was measured using a laser particle counter manufactured by Rion. The target particle size was 0.3-0.4 μm.
(3) PF value The PF value, which is an index of the filter performance of the filter medium, was obtained from the following equation (1) using the data of (1) and (2). The higher the PF value, the lower the transmittance at the same pressure loss or the lower pressure loss at the same transmittance.
(5) Tensile strength A test piece cut to 1 inch width × 130 mm length was collected from the filter medium, and using a constant speed tensile tester (Toyo Seiki Seisakusho; Strograph M1) with a span length of 100 mm and a tensile speed of 15 mm / min. It was measured.
(6) Water repellency The water repellency was measured according to MIL-STD-282.
(7) Flame retardancy Flame retardancy is measured according to JACA No. It measured with the combustibility tester (Suga test machine; UL-94HBF) based on 11A-2003. In the evaluation, those satisfying the flammability classification class 3 were evaluated as ◯, and other cases were evaluated as ×.
これらの試験の測定結果を表1及び表2に示す。 Tables 1 and 2 show the measurement results of these tests.
比較例1は従来例に相当し、比較例2は単純にその坪量を半減させた例であるが、比較例1と2においては、坪量が80g/m2から40g/m2に半減した結果、引裂強さ、引張強さ、撥水性が大きく低下した。これに対して、実施例1と5においては、それぞれ0.1dtexのポリエステル短繊維、又はアクリル短繊維を10質量%配合した結果、坪量40g/m2においても比較例1の坪量80g/m2と同レベル以上の引裂強さと撥水性を達成できた。ただし、引張強さの改善効果は小さいが、このレベルでも濾材加工性には問題がない。実施例4、6では、繊維径と配合率を変えて実施して同様に効果が見られた。一方、繊維径5μmより太い化合繊短繊維を配合した比較例3、4では、引裂強さと撥水性の向上は少なかった。実施例2、3においては、0.1dtexポリエステル短繊維の配合を増量した結果、坪量25g/m2まで低減しても引裂強さと撥水性は問題ないレベルであった。ただし、実施例3、8のように化合繊短繊維の配合率が22質量%を超えると、難燃性が悪化した。難燃性が要求される用途では、実施例9からわかるように化合繊短繊維の配合率を22質量%以下とする必要性がわかった。また、実施例8からわかるように配合率が化合繊短繊維の30質量%のときにDOP透過率及びPF値は許容レベルであったが、比較例6のように配合率が化合繊短繊維の30質量%を超えるとDOP透過率の増大及びPF値の低下が見られた。逆に、化合繊短繊維の配合率を減らし5質量%とした実施例7では、効果は十分にあったが、配合率を更に減らして3質量%とした比較例5では、引裂強さと撥水性が低下した。バインダーを親水性のポリビニルアルコール(PVA)バインダー繊維に変更した比較例7では引裂強さと撥水性が著しく低下し、比較例8ではバインダーに加えて化合繊短繊維を親水性の0.6dtexビニロン繊維に変更して更に引裂強さと撥水性が低下した。親水性の化合繊短繊維とバインダーは引裂強さの向上にほとんど効果が無く、逆に撥水性を低下させてしまうと考えられる。実施例10のアクリル樹脂バインダーが対濾材3質量%であるときと比較して、アクリル樹脂バインダーが対濾材2質量%の比較例9は、引裂強さ、引張強さ、撥水性に劣った。実施例11のアクリル樹脂バインダーが対濾材10質量%であるときと比較して、アクリル樹脂バインダーが対濾材11質量%の比較例10は、DOP透過率の増大及びPF値の低下が見られた。 Comparative Example 1 corresponds to a conventional example, and Comparative Example 2 is an example in which the basis weight is simply halved, but in Comparative Examples 1 and 2, the basis weight is halved from 80 g / m 2 to 40 g / m 2 . As a result, tear strength, tensile strength, and water repellency were greatly reduced. On the other hand, in Examples 1 and 5, as a result of blending 10% by mass of 0.1 dtex polyester short fiber or acrylic short fiber, the basis weight of Comparative Example 1 was 80 g / m 2 even at a basis weight of 40 g / m 2 . The tear strength and water repellency of the same level as m 2 or more could be achieved. However, although the effect of improving the tensile strength is small, there is no problem with filter medium workability even at this level. In Examples 4 and 6, the effect was similarly observed when the fiber diameter and the blending ratio were changed. On the other hand, in Comparative Examples 3 and 4 in which compounded synthetic short fibers having a fiber diameter larger than 5 μm were blended, there was little improvement in tear strength and water repellency. In Examples 2 and 3, as a result of increasing the blending of 0.1 dtex polyester short fibers, the tear strength and water repellency were at a level with no problem even when the basis weight was reduced to 25 g / m 2 . However, when the compounding ratio of the synthetic fiber short fibers exceeded 22% by mass as in Examples 3 and 8, the flame retardancy deteriorated. In applications where flame retardancy is required, as can be seen from Example 9, it was found that the compounding ratio of the synthetic fiber short fibers should be 22% by mass or less. Further, as can be seen from Example 8, the DOP transmittance and the PF value were acceptable when the blending ratio was 30% by mass of the synthetic fiber short fibers, but the blending ratio was as in Comparative Example 6 but the compound fiber short fibers. When the content exceeds 30% by mass, an increase in DOP transmittance and a decrease in PF value were observed. On the contrary, in Example 7 in which the compounding ratio of the synthetic fiber short fibers was reduced to 5% by mass, the effect was sufficient, but in Comparative Example 5 in which the compounding ratio was further reduced to 3% by mass, the tear strength and the repellency were increased. Aqueousness decreased. In Comparative Example 7 in which the binder is changed to hydrophilic polyvinyl alcohol (PVA) binder fiber, tear strength and water repellency are remarkably reduced. In Comparative Example 8, in addition to the binder, the synthetic short fiber is hydrophilic 0.6 dtex vinylon fiber. The tear strength and water repellency were further reduced. It is considered that hydrophilic synthetic short fibers and binders have little effect on improvement of tear strength, and conversely reduce water repellency. Compared to the case where the acrylic resin binder of Example 10 was 3% by mass of the filter medium, Comparative Example 9 in which the acrylic resin binder was 2% by mass of the filter medium was inferior in tear strength, tensile strength, and water repellency. Compared with the case where the acrylic resin binder of Example 11 was 10% by mass of the filter medium, Comparative Example 10 in which the acrylic resin binder was 11% by mass of the filter medium showed an increase in DOP transmittance and a decrease in the PF value. .
Claims (3)
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PCT/JP2010/057005 WO2010122999A1 (en) | 2009-04-24 | 2010-04-20 | Low-basis-weight filter media for air filters |
US13/255,585 US20120031063A1 (en) | 2009-04-24 | 2010-04-20 | Low-basis-weight filter media for air filters |
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WO2010122999A1 (en) | 2010-10-28 |
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CN102405088A (en) | 2012-04-04 |
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US20120031063A1 (en) | 2012-02-09 |
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